System for facilitating fluid movement in closed molds

Abstract

A vacuum bagging system may include a layer assembly defining a fluid flow channel. The layer assembly may include a contact layer mounted to a composite part positionable within an outer mold line (OML) tool. The contact layer may have a contact layer width defined by opposing contact layer side edges. The layer assembly may further include an inner layer mounted to the contact layer and having inner layer side edges located between the contact layer side edges. The fluid flow channel may extend along at least a portion of the composite part to at least one part end. The vacuum bagging system may include an internal vacuum bag positionable against the inner layer. An inner mold line (IML) tool may support the internal vacuum bag. The contact layer width may be less than an IML tool width.

What is claimed is: 
     
       1. A vacuum bagging system, comprising:
 a layer assembly defining a fluid flow channel and including:
 a contact layer mounted to a composite part positionable within an outer mold line tool and having a contact layer width defined by opposing contact layer side edges; 
 an inner layer mounted to the contact layer and having inner layer side edges located between the contact layer side edges; 
 the fluid flow channel formed by a combination of the inner layer and the contact layer and extending along at least a portion of the composite part to at least one part end; 
 
 an internal vacuum bag positionable against the inner layer; 
 an inner mold line tool supporting the internal vacuum bag; and 
 the contact layer width being less than an inner mold line tool width. 
 
     
     
       2. The vacuum bagging system of  claim 1  wherein:
 the layer assembly is positioned such that a contact layer side edge is located adjacent to and outside of an inside corner of the composite part. 
 
     
     
       3. The vacuum bagging system of  claim 1  wherein:
 the contact layer has a contact layer width of between 0.5 and 3.0 inch. 
 
     
     
       4. The vacuum bagging system of  claim 1  wherein:
 the contact layer has a contact layer thickness of no greater than approximately 0.005 inch. 
 
     
     
       5. The vacuum bagging system of  claim 1  wherein:
 the contact layer is formed of fluorinated ethylene propylene. 
 
     
     
       6. The vacuum bagging system of  claim 1  wherein:
 the inner layer has an inner layer thickness of no greater than approximately 0.050 inch. 
 
     
     
       7. The vacuum bagging system of  claim 1  wherein:
 the internal vacuum bag has a thickness of no greater than approximately 0.020 inch. 
 
     
     
       8. The vacuum bagging system of  claim 1  wherein:
 the contact layer, the inner layer, and the internal vacuum bag have a collective layer assembly thickness of no greater than approximately 0.10 inch. 
 
     
     
       9. The vacuum bagging system of  claim 1  wherein:
 at least one of the contact layer and the inner layer is removably secured to the composite part at one or more discrete locations along a contact layer length. 
 
     
     
       10. The vacuum bagging system of  claim 9  wherein:
 at least one of the contact layer and the inner layer is removably secured to the composite part with pressure-sensitive adhesive tape. 
 
     
     
       11. The vacuum bagging system of  claim 1  wherein:
 the inner layer comprises a plurality of inner layers. 
 
     
     
       12. The vacuum bagging system of  claim 1  wherein:
 the internal vacuum bag is comprised of at least two layers including a part-side bag layer and a non-part side bag layer; 
 the part-side bag layer being in contact with the inner layer, and the non-part side bag layer being in contact with the inner mold line tool; and 
 the part-side bag layer being formed of material that is chemically non-reactive with composite part material. 
 
     
     
       13. A vacuum bagging system, comprising:
 a layer assembly defining a fluid flow channel and including:
 a contact layer mounted to a composite part positionable within an outer mold line tool and having a contact layer width defined by opposing contact layer side edges; 
 an inner layer mounted to the contact layer and having inner layer side edges located between the contact layer side edges; 
 the fluid flow channel formed by a combination of the inner layer and the contact layer and extending along at least a portion of the composite part to at least one part end; 
 
 an internal vacuum bag positionable against the inner layer; 
 an inner mold line tool supporting the internal vacuum bag and having an inner mold line tool width being greater than the contact layer width; and 
 an external vacuum bag mounted to the outer mold line tool and fluidly coupling the fluid flow channel to a vacuum source. 
 
     
     
       14. The vacuum bagging system of  claim 13  wherein:
 the layer assembly is positioned such that a contact layer side edge is located adjacent to and outside of an inside corner of the composite part. 
 
     
     
       15. The vacuum bagging system of  claim 13  wherein:
 at least one of the contact layer and the inner layer is removably secured to the composite part at one or more discrete locations along a contact layer length. 
 
     
     
       16. The vacuum bagging system of  claim 13  wherein:
 the contact layer is porous in a through-thickness direction. 
 
     
     
       17. The vacuum bagging system of  claim 13  wherein:
 the contact layer is porous along a lengthwise direction of the composite part. 
 
     
     
       18. The vacuum bagging system of  claim 13  wherein:
 the inner layer is porous along a through-thickness direction. 
 
     
     
       19. The vacuum bagging system of  claim 13  wherein:
 the inner layer is porous along a lengthwise direction of the composite part. 
 
     
     
       20. A vacuum bagging system for processing a composite part, comprising:
 a layer assembly defining a fluid flow channel and including:
 a strip of contact layer mounted along a first portion of an inner surface of a composite part having a three-dimensional geometry and being positionable within an outer mold line tool, the strip of contact layer extending from a part interior of the composite part to at least one part end of the composite part and having a contact layer width defined by opposing contact layer side edges, the strip of contact layer being located adjacent to and outside of a second portion of the composite part such that an internal vacuum bag positioned on a side of the inner layer opposite the contact layer applies vacuum pressure directly onto the inner surface of the second portion not covered by the strip of contact layer; 
 a plurality of strips of inner layer each having an inner layer width that is no greater than the contact layer width and being positioned between the contact layer side edges; 
 the fluid flow channel formed by a combination of the strip of contact layer and the strips of inner layer and extending along at least a portion of the composite part to the at least one part end; 
 
 an inner mold line tool supporting the internal vacuum bag on a side thereof opposite the strips of inner layer and having an inner mold line tool width, the inner mold line tool configured as at least one of a bag carrier and a mandrel for supporting the internal vacuum bag and being configured complementary to the inner surface of the composite part; and 
 the contact layer width being less than the inner mold line tool width.